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Old 05-22-2011, 01:40 PM   #1
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1998 TJ gas tank mod 15 to 19

I was having some trouble with my fuel gauge jumping around and determined it was sending unit so I thought while I had the tank off I thought I would check out the mod for changing it to a 19 gal tank by cutting off the fill/vent tube inside the tank.

I know I have the 15 gal tank, there is a part number on the tank you can check inside the wheel well drivers side. Mine is 52018687AB which is 15 gal.

I drained the tank completely and removed it, removed the pump/sending unit and checked inside the tank, sure enough the fill tube and vent tube stick about 6 inches into the tank. I used a keyhole saw to cut them off about an inch into the tank, they are plastic. I have read you only need to cut the vent tube, I cut them both. I believe you could use a razor knife also. I cleaned the tank out and hit the sending unit with carb cleaner, it was dirty, reassembled and put the tank back in.

I put 5 gallons of gas in then drove to the gas station and put 13.73 gallons in hence 18.73 gallons.

I appears cleaning the sending unit fixed the gauge problem as well.

There you have it, 2 hour free mod and get an extra 60 miles range, well worth it. Ive read that your fuel gauge will just stay on full longer until you have used up the extra 4 gallons.

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Old 05-22-2011, 01:48 PM   #2
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Any pics?

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Old 05-22-2011, 03:37 PM   #3
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Sorry no pics.
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Old 05-22-2011, 03:48 PM   #4
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pics or it didnt happen
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Old 05-22-2011, 04:05 PM   #5
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Too funny...
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Old 05-22-2011, 05:28 PM   #6
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Glad this benefited you. Ford diesel trucks have the same issue and this mod is commonly called a "harpoon mod". Most of us use PVC cutters to cut the fill and vent tube as close to flush as we can. The PVC cutter uses a large razor blade to make a smooth cut so no saw dust, burs, or shavings to deal with.
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Old 05-24-2011, 12:55 AM   #7
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Wish you'd do it again and take some pictures - I'd love to do this.
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Old 05-24-2011, 09:29 PM   #8
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Artist Rendition

Here is an artists rendition of the mod.
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Old 05-24-2011, 09:41 PM   #9
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You do know that they are 19gal right? At least my '97 is from the factory...
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Old 05-24-2011, 10:03 PM   #10
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That is what the mod is for, they are all 19 gal tanks. My base model came with a "15 gallon" you have to cut the tubes in order to fill to 19 gallons. You had to pay extra for the "19 Gallon tank".
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Old 05-26-2011, 10:12 AM   #11
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I know ive hear of this mod before but i just dont see how removing a tube or two will free up that much room fro an extra 4 gallons or so. oh and by the way, love your stick figure drawing lol
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Old 05-26-2011, 10:33 AM   #12
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I know my jeep will take 18.2 gallons with out changing anything and those two hoses are still in place (98). I believe the 4 cylinders came with the 15 and the 6's came with the 19.

I believe by shortening it, because it is on an angle you raise the point where the fuel starts to cover the vent hole, which i believe is part of what trips the gas nozzel off.

You could also try parking on a slight incline so the passenger side is lower than the drivers side...
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Old 05-30-2011, 02:13 PM   #13
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The tubes themselves do not take up 4 gallons of space. It has to do with when and how the nozzle gets tripped to shut off. You can "milk" the extra 4 gallons but it takes more time to get the last 4 gallons in than it does for the previous 15.
Here is the type of cutter I use to cut the tubes. No mess and makes very quick work in one snip per tube.
General Tools 119 PVC Pipe Cutter
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Old 06-01-2011, 04:26 PM   #14
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Talking

Quote:
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Here is an artists rendition of the mod.
Best post of the year!

[right click] [save as]...
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Old 06-01-2011, 08:34 PM   #15
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Thanks for the stick figure comments...LOL
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Old 06-02-2011, 02:03 PM   #16
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Quote:
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here is an artists rendition of the mod.
omglol!!!
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Old 06-06-2011, 03:11 AM   #17
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That's a cool free mod! I never knew about this one. Maybe someday I'll do it haha.

I think you are a natural artist. Hahahah
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Old 06-09-2011, 06:57 AM   #18
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On my 06 Dodge I added a vent to the highest point on the tank and put a "T" in the factory vent tube. Its only a 35 gal factory, after the new vent its 39.5 gal. And when filling, it doesnt pop off the gun its actually full!
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Old 12-22-2011, 02:40 PM   #19
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You should've only cut the actual vent tube, not both.
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Old 12-29-2011, 06:03 AM   #20
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Jeep TJ gas tank mod
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You should've only cut the actual vent tube, not both.
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Old 02-03-2012, 01:56 PM   #21
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is there any aftermarket gas tank that holds more than the 19 gal stock that can be bought? If so anyone know where to get?
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Old 02-03-2012, 02:54 PM   #22
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Genright has a 22 gallon
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Old 04-08-2012, 08:24 AM   #23
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Digging this thread back up because I'm having a gauge/sender issue.

Can't I just get the pump/sender for the 19 gallon tank from a 4.0 model and install it in my SE?

I ask because I suspect my sender is shot, and if removing it and cleaning it up doesn't fix it, I'll replace it anyway.

I'm guessing that since all TJs have the same tank, the fue pump/sending unit is the same except for the longer neck/vacuum tubes, right?

And just to clarify, I have to replace both because the pump and sender are all one unit, right?
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Old 04-08-2012, 05:06 PM   #24
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I replaced the sending unit alone on mine, dealer about 30 bucks....and it came with a new gas tank seal ring. As far as the 15/19 sending unit I don't know if they are interchangeable.
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Old 03-24-2013, 04:16 PM   #25
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PLEASE HELP. I am in the middle of this mod and managed to break the two plastic clips on the top of the fuel sending unit that are used to clamp down the fuel pressure regulator. Can I do without clamping the fuel pressure regulator down and just reinstall everything or will the Jeep not run correctly? Need help quickly bc my jeep is sitting in the garage completely disassembled.

Thanks.
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Old 03-24-2013, 04:43 PM   #26
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Here is an artists rendition of the mod.
This pic alone should become a sticky!
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Old 03-24-2013, 10:06 PM   #27
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PLEASE HELP. I am in the middle of this mod and managed to break the two plastic clips on the top of the fuel sending unit that are used to clamp down the fuel pressure regulator. Can I do without clamping the fuel pressure regulator down and just reinstall everything or will the Jeep not run correctly? Need help quickly bc my jeep is sitting in the garage completely disassembled.

Thanks.
I really don't see a way to hold down the regulator without drilling holes through the top and I don't think you want to do that. You might have to pick up a new unit. Here is one on e-bay for 14 bucks for a 97. Jeep TJ Wrangler Fuel Pump Sending Unit 97 02 | eBay
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Old 03-27-2013, 05:59 PM   #28
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I really don't see a way to hold down the regulator without drilling holes through the top and I don't think you want to do that. You might have to pick up a new unit. Here is one on e-bay for 14 bucks for a 97. Jeep TJ Wrangler Fuel Pump Sending Unit 97 02 | eBay
Hey thanks for the response. I ended up buying a completely new fuel sender unit that came with a new pump, filter, and pressure regulator. Given that the original unit was still on the TJ built in '99, it is good insurance. Cost me around $200 on Amazon for the Omix-Ada part. Talk about a product that is hard to decide which brand to go with. The local stores only carry Airtex which get horrible reviews online, so I ended up ordering on Amazon and got the Omix-Ada.

Last night I have the new sending unit in and have the tank jacked up to about the point where I can connect the fuel lines again and the electric plug to the fuel pump. I grab the fuel pump cable from the new sending unit and the old cable leading to the front of the Jeep and I literally almost crap my pants. THE BRAND NEW OMIX-ADA UNIT HAS A FEMALE ELECTRICAL LEAD. The OEM unit has a male lead and the wiring harness going to the front of the engine has a female lead. WTF!

I keep my cool and cut off the old cable attached to the old sending unit, cut, crimp, and solder the old sending unit male lead to the new sending unt and thankfully everything appears to be running.

I plan to send a complaint to Amazon about the pump (the one I bought is sold by Amazon). Talk about a manufacturer defect!
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Old 03-28-2013, 03:31 PM   #29
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Glad you got it going...the "extra 4 gallons" comes in handy for sure.
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Old 03-31-2013, 07:36 PM   #30
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Ive heard about this mod & since I have to drop the tank to install my skid I am going to do it.I plan on getting a new fuel pump since mine has 140k sooo I will need to get a 19 gal sending unit,correct.

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